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For decades now, the foundation of the world’s modern infrastructure is highly reliant on the cement industry. It is the primary construction material for the homes we live in, the roads and bridges we travel upon, and commercial and industrial spaces, too. However, the production of cement requires a lot of energy and thus results in substantial carbon emissions worldwide.
The cement sector is associated with around 7-8% of the globe’s CO, thus becoming one of the biggest CO emitters. As such, there’s enormous stress on the cement companies across the world to include clean methods as well as green methods of energy that adhere to the sustainability concerns in the long run.
But things are changing now. Across India and the globe, cement manufacturers are switching over to solar power, wind energy and waste heat recovery to manufacture cement. This is not just helping in fighting global climate change, but changing the way an entire industry thinks about its manufacturing habits, and their long-term growth.
Why Does Cement Manufacturing Require Energy Use?
Cement manufacturers require intense heat for cement production. Limestone is heated to about 1,450°C in a rotary kiln, which cooks it into the key component of cement – clinker. Cement manufacturing uses a massive amount of fuel for this heating process. Most of it is fossil fuels like coal and gas.
Manufacturing cement requires:
- Huge amounts of electricity for crushing and grinding materials
- Large amounts of fossil fuels to produce heat and power
This is the reason why sustainable cement manufacturing has become so essential today.
Responsible cement manufacturers across India are investing in finding and building cleaner versions of their cement manufacturing process. Green cement production is not just a trend but a serious commitment to a more sustainable future.
What Role Does Renewable Energy Play in Cement Production?
The role of fossil fuels is being substituted by renewable energy by cement manufacturers in India to meet the requirements of sustainable cement production.
- Solar energy meets the power requirements of the plant and captive power units
- Wind power enables a consistent supply of electricity to the grinding units
- Waste heat recovery system (WHRS) captures the wasted heat produced from manufacturing and utilises it again, instead of releasing it outside into the atmosphere.
Beyond its potential to free up reliance on a non-renewable infrastructure, the integration of renewable energy allows cement manufacturers to realise a substantial reduction of Scope 2 emissions – indirect GHG emissions caused by the purchase of electricity. These efforts can, for example, come from an on-site system of solar arrays, a wind turbine and a heat-capturing device for process waste.
By FY 2024, major Indian cement manufacturers installed more than 1800MW capacity of renewable energy, with 42% of it coming from waste heat recovery systems and the rest 58% from Solar and Wind energy. Additionally, there is a plan to add 5 GW of renewable energy capacity by 2030.
According to the International Energy Agency (IEA), increasing the use of renewable energy and improving energy efficiency are among the most important strategies for reducing carbon emissions across energy-intensive industries such as cement manufacturing.
The use of sustainable cement manufacturing is no longer optional, but it is becoming a standard for leading Indian cement manufacturers.
How Are Cement Manufacturers in India Adopting Renewable Energy?
India is the world’s second-largest producer of cement. Presently, only about 3% of the sector’s electricity consumption comes from renewable sources, and11% is sourced through waste heat recovery systems. It seems modest by current standards, but the trends are set, and the momentum is building.
The good news is that a number of the large cement manufacturers are already practising green cement production. At MP Birla Cement, the manufacturing process has incrementally built up its own capacity in renewables over the years. Its array of solar power projects at a number of its plants, along with their waste heat recovery technologies, where the heat from the kilns is captured instead of being sent out as wasted heat, now totals up to nearly 90 MW of green energy capacity.
This goes to show that sustainable cement production has become the new industry standard, and cement manufacturers are integrating green cement production within the day-to-day operations of their factories.
For both consumers and builders, green cement production has more advantages than you think. Purchasing a product manufactured sustainably means that you’re contributing to a greener construction ecosystem.
How Does Waste Heat Recovery Actually Work?
This technology deserves its own explanation because it’s one of the simplest and most effective tools cement plants use today.
During production, kilns release a huge amount of heat that would otherwise just escape into the atmosphere. Waste Heat Recovery Systems capture this heat and convert it into electricity, which is then used to power parts of the plant.
Instead of letting hot exhaust go to waste, the plant reuses it, almost like recycling energy that was already being generated. It doesn’t require additional fuel, and it directly reduces a plant’s dependence on the grid or on fossil-fuel-based power. This is one of the easiest entry points for green cement production, which is why it’s now used across 42% of installed renewable capacity in the Indian cement manufacturing sector.
Conclusion
There are more advantages to renewable energy use than efficiency during manufacturing. Using renewable energy in cement production will also allow for green building certifications by making it easier for your project to achieve environmentally acceptable performance standards and sustainability specifications.
Renewable energy is making a huge difference in how we produce cement. Solar panels, wind turbines, and waste heat recovery systems are all turning points for companies looking to cut down on carbon emissions.
With sustainable infrastructure continuing to gain momentum, green cement production and sustainable cement manufacturing will continue to grow and evolve. Cement manufacturers like MP Birla Cement, which transition to renewable energy sources and sustainable production practices, are better poised to handle construction demands in the coming years and help build a more sustainable future.
FAQs
Q.What is green cement production?
Green cement production processes utilise renewable sources of energy and fuels to reduce our carbon footprint while continuing to ensure high-quality, durable, and long-lasting concrete. It’s a process where companies can remove the ‘carbon’ from ‘carbon concrete.’
Q.What renewable energy sources are used in cement plants?
Solar power, wind energy, and waste-derived alternative fuels are the most popular types of renewable energy sources that cement plants utilise. They minimise the impact on the environment, and so cement manufacturers use green cement production practices.
Q.What are the economic benefits of using renewable energy in cement manufacturing?
With renewable energy, cement manufacturers will see their long-term energy costs drop, they will avoid volatile fuel price movements and gain more efficiencies to make themselves more cost competitive. And while investment in renewable energy infrastructure may initially look steep, the fuel cost will be recouped in the long run and in some cases, renewables could bring a competitive edge in helping them meet corporate environmental sustainability targets.
Q.Can renewable energy fully replace fossil fuels in cement plants?
Right now, fully substituting fossil fuels is not an option at all cement plants, since this type of industrial activity requires very high temperatures, and clean energy is not always enough. Although it is possible to lessen reliance on fossil fuels and make production cleaner.